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2. 1 colored Pool noodle
3. 1' of 1/2 foam pipe insulator
4. Duct tape (not shown)
5. 10 minutes
6. Tape measure (optional)
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http://www.youtube.com/watch?v=BU6fNCxraIM
or
http://www.bobafettm.com/eryndor/page_gear/gear.htm
By the way, these types of foam-covered weapons are typically called "boffer" weapons. There are various groups across the US who come together over the weekend to fight with these, and there's even a small cottage industry to make the weapons.
Here's a good link to learn more:
Lukrain's Guide to Boffers